Protective sports helmet with energy-absorbing padding and a facemask with force-distributing shock absorbers

ABSTRACT

A protective helmet having a layer of foam covering the hard shell of the helmet configured such that the foam absorbs shock from an impact thereby decreasing the amount of force translated to the head, neck, or spine of the wearer. A force-distributing shock absorber coupled to a helmet and facemask to protect the jaw from shock impacts.

BACKGROUND OF THE INVENTION

1. Technical Field

The invention relates generally to protective headgear. More specifically, the invention relates to a protective sports helmet with energy-absorbing padding and a facemask with force-distributing shock absorbers.

2. Description of the Related Art

The potential for an individual suffering a head injury while participating in a sporting activity depends upon the type of sport as well as the skill of its participants. High impact sports necessitate the use of the headwear; however, head injuries still occur despite participant skill. Headwear protection must also be capable of withstanding repeated impacts without imparting injury to the individual.

Headwear designed to protect an individual's head from injury is commonly referred to as a helmet. Proper helmet construction cannot be emphasized enough when used in such sports as football. In fact, it is a requirement that high school, college, and professional football players wear a helmet during play. Typically, these helmets have included: an outer shell, generally made of an appropriate plastic material, having the requisite strength and durability characteristics to enable them to be used in the sport of football; some type of shock absorbing liner within the shell; a face guard; and a chin protector, or chin strap, that fits snugly about the chin of the wear of the helmet, in order to secure the helmet to the wearer's head, as are all known in the art.

When a user's head impacts a hard object while wearing a helmet, some of the energy of the impact is absorbed and displaced by the padding as it compresses against and between the user's head and the outer casing. However, despite the mandated requirement for helmet use and construction, head injuries still occur in notable numbers.

The rule makers for football have recognized the importance of the helmet and face mask combination and have imposed rules to help to reduce injuries. However, a rule in itself cannot prevent injury and/or maiming of a player. Such a rule can only invoke a yardage penalty, a fine, or at worst a suspension of a player. The injury and associated damage, however, will have still occurred to the victim player.

Head trauma and head injuries are some of the most under diagnosed and misunderstood afflictions in sports. As more and more data and information comes to light regarding athletes and concussions, the closer sports and medical professionals come to finding a workable solution and possibly better prevention methods.

In fact, the United States Congress has recently considered a study performed at the University of Michigan that revealed that football players who suffer head injuries have much higher rates of dementia and cognitive disabilities later in their lives. In response, the National Football League has announced that it will conduct scientific research that will give players and equipment managers more information about helmets and will help manufacturers know where they could improve equipment.

Numerous helmet manufacturers have developed various helmet designs and materials of construction in an effort to reduce head injury. As mentioned above, the common element in all such helmets is that the outer skeletal shell is constructed of an impact resistant hard plastic shell which operates to protect the wearer's head and spine should the individual wearing such a helmet impact another person or another obstacle. However, known solutions do not adequately address the risk of head injury as evidenced by the staggering amount of head injuries that still occur.

Additionally, during sporting events, blows are commonly directed to the chin or jaw. When a heavy blow is delivered to the chin, the force extends into the jaw joint. The forces are transmitted to major nerves at the base of the brain, to the blood supplies to the brain, as well as to the balance center located near the jaw joint. In short, this force can leave the athlete with a concussion. Scientific studies and practical experience time and again have demonstrated the effectiveness of chin and jaw protection in the prevention of concussion.

Additionally, a helmet wearer's comfort is an additional concern to designers. Notably, a helmet should allow warm air to escape the helmet through vents and allow breathability. Accordingly, a helmet is needed which provides superior breathability, padding, and impact resistance for the user, while simultaneously offering more resilient external surfaces for contact with opposing objects. A player should have confidence that a head injury can be avoided through the use of such equipment. Likewise, a helmet is needed which provides superior protection to chin and jaw impact.

SUMMARY OF THE INVENTION

The invention relates to a helmet having a layer of foam covering the hard shell of the helmet and a shock absorbent facemask. According to some embodiments, a helmet is configured such that the foam absorbs shock from an impact thereby decreasing the amount of force translated to the head, neck, or spine of the wearer.

In some embodiments of the invention, more foam is placed in areas that protect against the most common impacts. In some embodiments of the invention, a flexible, durable plastic covering covers the foam. The plastic covering is preferably paintable and does not freeze during common sports conditions. In some embodiments the shell and the foam covering include ventilation holes to allow for breathability.

In some embodiments of the helmet couples with the facemask of the helmet with a force-distributing shock absorber to protect the jaw from shock impacts. In some embodiments, the force-distributing shock absorber includes a snap-on coupling. In some other embodiments, the force-distributing shock absorber includes a quick-release coupling.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an isometric view of a basic protective helmet of the prior art;

FIG. 2A illustrates a cross-sectional view of an improved helmet according to some embodiments of the invention;

FIG. 2B illustrates a front view of a helmet having a shell, a layer of foam, ventilation holes, and gaps in the foam according to some embodiments of the invention;

FIG. 2C illustrates a cross-sectional view of a helmet with a layer of shock absorbent foam with a deformable polymer outer-shell according to some embodiments of the invention;

FIG. 2D illustrates a front view of a helmet with a layer of shock absorbent foam with a deformable polymer outer-shell according to some embodiments of the invention;

FIG. 3 illustrates an isometric detail of a helmet coupled with a facemask via a shock-absorbent facemask coupling mechanism according to some embodiments of the invention;

FIG. 4A is an overhead view of the shock-absorbent facemask coupling mechanism and a vertical member of the facemask via a snap-on, c-shaped clip according to some embodiments of the invention;

FIG. 4B is an overhead view of the shock-absorbent facemask coupling mechanism coupled with a vertical member of the facemask via a snap-on, c-shaped clip according to some embodiments of the invention;

FIG. 5A is an overhead view of the shock-absorbent facemask coupling mechanism and a vertical member of the facemask via a u-shaped clip and a securing strap according to some embodiments of the invention; and

FIG. 5B is an overhead view of the shock-absorbent facemask coupling mechanism coupled with a vertical member of the facemask via the u-shaped clip according to some embodiments of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The invention comprises an improved protective helmet. Helmets are configured to protect a wearer's head, face, and spine from a plurality of impact forces. FIG. 1 illustrates an isometric view of a basic protective helmet 100 of the prior art. The helmet 100 includes a shell 101 configured to receive the head of a wearer of the helmet 100. The helmet 100 comprises a front region 102, a crown region 103, a rear region 104, two side regions 105, a jaw protection region 106, a chin strap 107, and a facemask 108. The helmet 100 of the prior art provides only a base level of protection against head impact and impact to the wearer's jaw and chin during a collision.

FIG. 2A illustrates a cross-sectional view of an improved helmet 200 according to some embodiments of the invention. The helmet 200 includes a shell 201 designed to securely receive the head of a wearer. In the presently preferred embodiments of the invention, the helmet 200 includes a layer of cushioning 299 coupled to the outer surface of a shell 201. For the remainder of the disclosure, the cushioning 299 is referred to as foam. However, it will be readily apparent to those with ordinary skill in the art having benefit of this disclosure that other suitable materials, now known or later developed, that decrease shock forces are equally suitable as cushioning.

The layer of foam 299 is configured to absorb impact forces on the wearer's head. In the presently preferred embodiments of the invention, the layer of foam 299 is permanently coupled with the shell 201 of the helmet 200.

In the presently preferred embodiments of the invention, the maximum thickness of the layer of foam falls within a range of 0.25 inches and 2.50 inches. In some embodiments the layer of foam 299 is contoured such that the layer is thinner in some areas and thicker in other areas. For example, in some embodiments of the invention, the foam 299 is thicker in areas most frequently impacted during the normal course of a sporting event.

In the presently preferred embodiments of the invention, the layer of foam has a density in the range of 0.75 pounds per cubic foot to 2.00 pounds per cubic foot. In some embodiments of the invention, the layer of foam 299 utilizes a plurality of foam regions, each one of which possibly uses different foam density values.

Although specific thickness and density values are specified herein, it will be readily apparent to those with ordinary skill in the art having the benefit of this disclosure that a wide variety of thicknesses and densities are feasible.

FIG. 2A shows the layer of foam 299 covering a front region 202, a crown region 203, and rear region 204 of the helmet 200. In some embodiments of the invention, the layer of foam covers fewer regions or more regions. For example, FIG. 2B illustrates a front view of a helmet 200 having a shell 201 with a layer of foam 299 covering front region 202, a crown region 203, and side regions 205 of the helmet 200 according to some embodiments of the invention.

Although specific examples of helmets are disclosed herein with placement of foam layers in specific regions, it will be readily apparent to those with ordinary skill in the art having the benefit of this disclosure that a helmet can include a foam layer in any region of the helmet.

While protection against shock impact is the primary purpose of a helmet, the helmet should also provide comfort and breathability. Referring again to FIG. 2B, the helmet 200 is configured with ventilation holes 275 disposed in the shell 201. According to some embodiments of the invention, the layer of foam 299 includes gaps 285 for letting the ventilation holes 275 breathe.

In some embodiments of the invention, the helmet 200 includes an outer-shell 298 covering a layer of foam 299. FIGS. 2C and 2D illustrate a cross-sectional view and a front view of a helmet 200 with a layer of shock absorbent foam 299 with a deformable polymer outer-shell 298 according to some embodiments of the invention.

In the presently preferred embodiments of the invention, the outer-shell 298 is a deformable polymer. The outer-shell 298 is preferably paintable such that a team logo, player number, etc. may be applied to the outer-shell 298. The outer-shell 298 also preferably maintains deformability at low temperatures. Although specific preferences are disclosed, it will be readily apparent to those having ordinary skill in the art that the outer-shell 298 can be composed of a number of different materials and have a number of different configurations.

As explained above, shocking blows to a human's chin or jaw can leave them with a concussion. Accordingly, some embodiments of the invention include a shock-absorbent facemask coupling mechanism to reduce the risk of injury to an athlete. FIG. 3 illustrates an isometric detail of a helmet 300 coupled with a facemask 350 via a shock-absorbent facemask coupling mechanism 375.

According to FIG. 3, the shock-absorbent facemask coupling mechanism 375 comprises an axial member 376 containing a dampening mechanism 377 for absorbing force components parallel to the axial member 376. For example, according to FIG. 3, the shock-absorbent facemask coupling mechanism 375 is configured such that forces components in the −z direction are absorbed by the dampening mechanism 377.

According to FIG. 3, the axial member 376 is coupled with an ear protection region 305 of the helmet 300. In some embodiments of the invention, the shock-absorbent facemask coupling mechanism 375 is fixed to the helmet 300. For example, FIG. 3 shows the shock-absorbent facemask coupling mechanism 375 fixed to the helmet 300 via a bolt 380. In some other embodiments, the shock-absorbent facemask coupling mechanism 375 is removably coupled to the helmet 300.

Likewise, in some embodiments of the invention, the shock-absorbent facemask coupling mechanism 375 is fixed to the facemask 350, while in other embodiments the shock-absorbent facemask coupling mechanism 375 is removably coupled to the facemask. FIG. 3 shows the shock-absorbent facemask coupling mechanism 375 coupled with a vertical member of the facemask 350 via a snap-on, c-shaped clip 360.

FIG. 4A is an overhead view of the shock-absorbent facemask coupling mechanism 475 and a vertical member 450 of the facemask extending in an out of the page. The shock-absorbent facemask coupling mechanism 475 comprises an axial member 476 containing a dampening mechanism 477 coupled with a shaft 478. The shaft 478 terminates with a snap-on, c-shaped clip 460. The axial member is coupled with a flange 479 having a conduit 481 disposed therein. The snap-on, c-shaped clip 460 is preferably a resilient material that deforms to expand. Accordingly, the snap-on, c-shaped clip 460 is configured to snap onto the vertical member 450 of the facemask.

Preferably the facemask extends far enough away from the wearer's chin such that the facemask does not impact the wearer's chin during full compression of the dampening mechanism 477.

FIG. 4B is an overhead view of the shock-absorbent facemask coupling mechanism 475 coupled with a vertical member 450 of the facemask via a snap-on, c-shaped clip 460. Additionally, according to FIG. 4B, a bolt 480 is inserted into the conduit 481 for coupling the shock-absorbent facemask coupling mechanism 475 with the helmet.

In some situations it may be desirable to provide a helmet having a shock-absorbent facemask coupling mechanism with a quick release feature such that the facemask can be opened without an application of force. For example, if a wearer experiences a neck injury while wearing the helmet, it is desirable to open the facemask and remove the helmet with as little force as possible to prevent further injury. Accordingly, some embodiments of the invention provide a shock-absorbent facemask coupling mechanism that uses a coupling that is easily removable.

FIG. 5A is an overhead view of the shock-absorbent facemask coupling mechanism 575 and a vertical member 550 of the facemask. The shock-absorbent facemask coupling mechanism 575 includes a u-shaped clip 560 and a securing strap 557 The shock-absorbent facemask coupling mechanism 575 comprises an axial member 576 containing a dampening mechanism 577 coupled with a shaft 578. The axial member is also coupled with a flange 579 having a conduit 581 disposed therein. The u-shaped clip 560 is configured to accommodate the vertical member 550 of the facemask. The u-shaped clip 560 also comprises a strap 557 with the female end of a snap 556 disposed on a first end of the strap 557 and a rivet 558 disposed on the other end of the strap 556 for coupling with the u-shaped clip 560. Likewise, the u-shaped clip 560 includes a male end of a snap 559. Accordingly, the u-shaped clip 560 is configured to fit onto the vertical member 550 of the facemask with the strap 556 securing it therein.

FIG. 5B is an overhead view of the shock-absorbent facemask coupling mechanism 575 coupled with a vertical member 550 of the facemask via the u-shaped clip 560. As shown, the female end of the snap 556 is snapped to the male end of the snap 559, thereby securing the shock-absorbent facemask coupling mechanism 575 with the vertical member 550. Additionally, according to FIG. 5B, a bolt 580 is inserted into the conduit 581 to couple the shock-absorbent facemask coupling mechanism 575 with the helmet.

Although the invention is described herein with reference to the preferred embodiment, one skilled in the art will readily appreciate that other applications may be substituted for those set forth herein without departing from the spirit and scope of the invention. Accordingly, the invention should only be limited by the Claims included below. 

1. A helmet comprising: a helmet shell configured to receive a head of a wearer of the helmet and configured to receive an impact force, wherein the helmet shell has a plurality of regions including: a crown region; a rear region; a front region; and two side regions; a layer of cushioning coupled to the outside of the helmet shell, wherein the layer of cushioning is configured to absorb at least a portion of said impact force; a faceguard configured to substantially cover the face, jaw, and chin of said wearer, wherein said faceguard is coupled with the front region of said helmet shell and to each of said two side regions via a shock-absorbent facemask coupling, said shock-absorbent facemask coupling comprising: an axial member extending parallel to an axis of a predominant force component of a force exerted on the chin and jaw of a wearer during a head-to-head collision between the wearer and another human; a dampening mechanism coupled to said axial member configured to at least partially resist said predominant force component of said force; and a quick-release mechanism configured to release said shock-absorbent facemask coupling.
 2. The helmet according to claim 1, further comprising an inner cushioning layer coupled with the inner surface of the our shell outer-shell.
 3. The helmet according to claim 1, wherein said layer of cushioning comprises a polymer foam.
 4. The helmet according to claim 3, wherein said foam is contoured over the surface of said shell such that said foam is thicker in regions most frequently impacted during normal sport.
 5. The helmet according to claim 3, wherein the thickness of said foam falls within a range between 0.25 inches and 2.50 inches.
 6. The helmet according to claim 3, wherein the density of said foam falls into a range between 0.75 pounds per cubic foot and 2.00 pounds per cubic foot.
 7. The helmet according to claim 1, wherein shell includes one or more ventilation holes disposed therein, and wherein said layer of cushioning includes one or more ventilation slits disposed therein, wherein one or more of said ventilation holes and one or more of said ventilation slits are substantially lined up, thereby exposing at least a portion of the head of the wearer to the environment.
 8. The helmet according to claim 1, further comprising a deformable polymer outer-shell coupled to an outside surface of said layer of cushioning.
 9. The helmet according to claim 8, wherein said deformable polymer outer-shell is paintable and does not freeze during environmental conditions normally associated with sports activity.
 10. The helmet according to claim 1, wherein said shock-absorbent facemask coupling couples with said facemask via a snap-on clip.
 11. The helmet according to claim 1, wherein said shock-absorbent facemask coupling couples with said facemask via clip, and wherein said clip includes a quick release strap mechanism for securing said facemask within the clip such that said coupling can be released by releasing said quick release strap mechanism.
 12. The helmet according to claim 1, wherein said layer of cushioning is permanently coupled with said shell.
 13. A helmet comprising: a shell configured to receive a head of a wearer of the helmet and configured to receive an impact force, wherein the shell has a plurality of regions including: a crown region; a rear region; a front region; and two side regions; a layer of cushioning coupled to the shell, wherein the layer of cushioning is configured to absorb at least a portion of said impact force.
 14. The helmet according to claim 13, wherein said layer of cushioning comprises a polymer foam.
 15. The helmet according to claim 13, wherein said layer of cushioning is permanently coupled with said shell.
 16. The helmet according to claim 14, wherein said foam is contoured over the surface of said shell such that said foam is thicker in regions most frequently impacted during normal sport.
 17. The helmet according to claim 14, wherein the thickness of said foam falls within a range between 0.25 inches and 2.50 inches, and wherein the density of said foam falls into a range between 0.75 pounds per cubic foot and 2.00 pounds per cubic foot.
 18. The helmet according to claim 13, wherein shell includes one or more ventilation holes disposed therein, and wherein said layer of cushioning includes one or more ventilation slits disposed therein, wherein one or more of said ventilation holes and one or more of said ventilation slits are substantially lined up, thereby exposing at least a portion of the head of the wearer.
 19. The helmet according to claim 13, further comprising a deformable polymer outer-shell coupled to an outside surface of said layer of cushioning.
 20. A helmet comprising: a shell configured to receive a head of a wearer of the helmet and configured to receive an impact force, wherein the shell has a plurality of regions including: a crown region; a rear region; a front region; and two side regions; a faceguard configured to substantially cover the face, jaw, and chin of said wearer, wherein said faceguard is coupled with the front region of said shell and to each of said two side regions via a shock-absorbent facemask coupling, said shock-absorbent facemask coupling comprising: an axial member extending parallel to an axis of a predominant force component of a force exerted on the chin and jaw of a wearer during a head-to-head collision between the wearer and another human; a dampening mechanism coupled to said axial member configured to at least partially resist said predominant force component of said force.
 21. The helmet according to claim 20, wherein said shock-absorbent facemask coupling couples with said facemask via a means selected from among: a snap-on clip; and a u-shaped clip, and wherein said u-shaped clip includes a quick release strap mechanism for securing said facemask within said u-shaped clip such that said coupling can be released by releasing said quick release strap mechanism. 